Packaging products and associated material

ABSTRACT

A packaging cushion includes a first liner and a second liner opposite one another and each defining an inner surface. A transverse liner axis extends normal to the inner surfaces. The packaging cushion includes a mesh bonded to and disposed between the first and second liners. The mesh has a top mesh surface and an opposed bottom mesh surface. The mesh defines a plurality of nodes and a plurality of legs interconnecting the plurality of nodes. Each of the plurality of nodes defines 1) a top node surface defined by the top mesh surface, 2) a bottom node surface defined by the bottom mesh surface, and 3) a transverse node axis extending substantially normal to the top and bottom node surfaces. The transverse node axes of at least some of the plurality of nodes are each oriented at an oblique angle relative to the transverse liner axis.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/720,538 filed on Sep. 29, 2017, the disclosure of which is herebyincorporated by reference in its entirety.

BACKGROUND

The present invention relates to packaging, and more particularly tostructure and function of packaging structures for shipping products.

Many common packaging products, such as, for example, padded envelopes(e.g, “jiffy mailers” or “bubble mailers”), are made from a combinationof paper-based materials and plastic-based materials bonded together.While the paper-based materials of the packaging product may berecyclable in a paper-based recycling facility and the plastic-basedmaterials may be recyclable in a plastic-based recycling facility, suchproducts need to be separated into their paper-based and plastic-basedmaterials prior to depositing them into a recycling bin, at least inmost areas or municipalities. Thus, such products, as received by aconsumer or other recipient, are not considered “curbside recyclable.”Unfortunately, such packaging products often find their way intolandfills or other garbage disposal sites.

The inventors of the present disclosure have identified that impartingdeformations in prior art paper-based packaging products, such as rigidcorrugated paperboard (also referred to as “cardboard” or “corrugate”),results in impairment of performance of such products because rigiditybecomes compromised. After rigid corrugated paperboard is folded,creased, and/or bent, portions thereof have localized weaknesses thatcan impair its protective functionality which relies substantially onrigidity. For example, certain types of corrugate possess a highcompressive strength yet, should a crease be formed therein, thecorrugate no longer exhibits protective functionality because itsstrength is compromised. Moreover, while certain features can beincorporated into paper-based packaging products to enhance strength,such features add complexity, and thus cost, to such packaging products.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be better understood when readin conjunction with the appended drawings, in which there is shown inthe drawings example embodiments for the purposes of illustration. Itshould be understood, however, that the present disclosure is notlimited to the precise arrangements and instrumentalities shown. In thedrawings:

FIG. 1 shows an exploded perspective view of constituent layers of apackaging cushion, including a cushion layer having a mesh, such as apaper-based mesh, according to an embodiment of the present disclosure;

FIG. 2 shows a top plan view of a packaging cushion including a mesh,with an outer layer of material omitted for visualization purposes,wherein the packaging cushion is similar to that shown in FIG. 1, andthe mesh is formed in a single piece of corrugate, according to anembodiment of the present disclosure;

FIG. 3 shows a top view of a portion of the mesh of FIG. 2 in an initialmesh configuration;

FIG. 4 shows a perspective view of a portion of the mesh of FIG. 2 inthe initial mesh configuration;

FIG. 5 shows a top view of a portion of the mesh of FIG. 2 in a firstexpanded configuration;

FIG. 6 shows a perspective view of a portion of the mesh of FIG. 5;

FIG. 7 shows a top view of a portion of the mesh of FIG. 2 in a secondexpanded configuration;

FIG. 8 shows a perspective view of a portion of the mesh of FIG. 7;

FIG. 9 shows a top view of a portion of a mesh according to anotherembodiment of present disclosure, wherein the mesh is formed in a pieceof kraft paper, and is shown in an initial mesh configuration.

FIG. 10 shows a top view of the portion of the mesh of FIG. 9 in anexpanded mesh configuration;

FIG. 11 shows a perspective view of the portion of the mesh of FIG. 10;

FIG. 12 shows an exploded perspective view of a padded envelopeemploying a cushioning layer, according to an embodiment of the presentdisclosure;

FIG. 13 shows a perspective view of a pair of padded envelopes employinga mesh cushioning layer;

FIG. 14 shows an end sectional view of a single-panel package employinga mesh packaging cushion, according to an embodiment of the presentdisclosure; and

FIG. 15 shows a schematic plan diagram of a system for making a meshpackaging cushion, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The embodiments of the present disclosure pertain to packaging productsand material used to form the padded mailer that includes a mesh cushionlayer that provides multi-directional flexibility and may also becurbside-recyclable at least with only trivial preparation. Theembodiments of the present disclosure include padded envelopes, forexample, that employ such cushion layers and are optionallycurbside-recyclable. As used herein with respect to packaging productsor portions thereof (such as a cushion or a cushioning layer, forexample), the terms “resilient”, “resilience”, “resiliency”, andderivatives thereof refer to an ability to at least partially recoverone's size and shape after deformation, particularly (though notexclusively) deformation responsive to compressive stress.

Referring to FIG. 1, a packaging cushion 2 includes a cushion layer 4disposed between a first outer layer of material 6 and a second outerlayer of material 8 such that the layers 4, 6, 8 define a laminar or“sandwich” structure. The outer layers 6, 8 can be referred to as an“outer liner” and an “inner liner”, or vice versa. FIG. 1 depicts thepackaging cushion 2 in an initial, substantially flat configuration, inwhich the outer layers 6, 8 and the cushion layer 4 are each elongatedin substantially planar manner along a longitudinal direction X and alateral direction Y that are substantially perpendicular to each other.The layers 4, 6, 8 also each have a thickness in a transverse directionZ that is substantially perpendicular to the longitudinal and lateraldirections X, Y. The transverse direction Z is denoted as the “Z”direction because it extends across the sandwich structure of the layers4, 6, 8. It is to be appreciated that the packaging cushion 2 can beflexible; thus, with respect to any location 10 on the packaging cushion2, the packaging cushion 2 defines a transverse axis 11 oriented alongthe transverse direction Z at the location 10, such that the transversedirection Z is substantially orthogonal to the outer layers 6, 8 at thelocation 10. When the packing cushion 2 is in the initial configuration,the transverse direction Z is substantially perpendicular to thelongitudinal and lateral directions X, Y.

The cushion layer 4 includes a flexible mesh 12 (also referred to hereinas a “mesh”), which includes a plurality of legs 14 extending between aplurality of nodes 16, as also shown in FIG. 2. Flexible mesh 12 may bemade of paper, metal, plastic, and/or other materials. The plurality oflegs 14 can interconnect the plurality of nodes 16. The legs 14 andnodes 16 can define a plurality of voids or “cells” 18 in the mesh 12extending between adjacent legs 14 and nodes 16 along the longitudinaland lateral directions X, Y. The legs 14 and nodes 16 can be arrangedinto patterns in a manner such that the cells 18 are also arranged intopatterns, as set forth in more detail below. It is to be appreciatedthat the packaging cushion 2 can itself be characterized as a piece ofcorrugate, with the outer layers 6, 8 fulfilling the role of the outerand inner liners and the mesh 12 fulfilling the role of the fluting.

In some embodiments, such as the present embodiment, the layers 4, 6, 8of the packaging cushion 2 can each be formed of one or more paper-basedmaterials that are curbside recyclable. As used herein, the term“curbside recyclable” means capable of being recycled in a recyclingfacility and/or in a recycling process available to the public throughmost municipal recycling programs. In some such embodiments, each of theouter layers 6, 8 can be formed substantially entirely of a packagingpaper, such as kraft paper or paperboard, by way of non-limitingexamples. Additionally, the mesh 12 can be formed substantially entirelyof kraft paper, paperboard, or corrugated paperboard (i.e., “cardboard”or “corrugate”). Thus, the packaging cushion 2 can be paper-recyclable.

A binder 20 can, for example, be disposed around a periphery 22 of themesh 12 in a manner attaching the mesh 12 to one or both of the outerlayers 6, 8. The binder 20 can be applied so as to contact the mesh 12primarily at peripheral nodes 16, as shown. However, in otherembodiments, the binder 20 can be applied so as to contact peripherallegs 14, or both peripheral legs 14 and peripheral nodes 16. In furtherembodiments, the binder 20 can be applied so as to contactnon-peripheral legs 14 and/or non-peripheral nodes 16. It is to beappreciated that the binder 20 can be applied so as to contact anycombination of legs 14 and/or nodes 16. The binder 20 can be anadhesive, such an adhesive strip (or strips), and/or a liquid-basedadhesive, such as an epoxy or glue, by way of non-limiting examples.Adhesive may alternatively or additionally be applied via aerosoldispersed throughout at least a portion of the space between the mesh 12and the adjacent outer layers 6, 8. In further embodiments, adhesive canbe applied to one or both of the inner surfaces 24 of the outer layers6, 8 in an evenly and/or unevenly distributed manner. For example, aneven coating of adhesive can be applied to one or both of the innersurfaces 24 of the outer layers 6, 8, which coating can adhere to theopposite side of the mesh 12. In yet other embodiments, adhesive can beapplied to one or both of the inner surfaces 24 of the outer layers 6, 8in a pattern, such as a zig-zag pattern, for example. Such a zig-zagpattern can optionally correspond to a pattern defined by the mesh 12.

The binder 20 may include recyclable and/or non-recyclable components.Many municipalities provide residential curbside recyclability forpackaging that includes small amounts of non-recyclable materials. Forthis reason, binder 20 may include conventional adhesives, such as thoseused in prior art corrugate boxes. Alternatively, or additionally,binder 20 may be a PLA-capable adhesive. In other embodiments, thebinder 20 can include an adhesive cord or string, such as a cottonand/or hemp-based adhesive string, for example. The binder 20 canconsist of one or more materials that are recyclable, such as RecyclingCompatible Adhesives (“RCAs”), such as Corvinax (e.g., Corvinax 324-39,Corvinax 379-05, Corvinax 418-01), for example.

Referring now to FIG. 2, a cushion layer 4 is shown with the first outerlayer 6 removed. The mesh 12 is shown attached to a support surface 24of the second outer layer 8 by the binder 20 extending around theperiphery 22 of the mesh 12. A second binder 26 can be disposed adjacenta periphery 28 of the second outer layer 8 and can be configured to bindthe second outer layer 8 to the first outer layer 6. As with the firstbinder 20, the second binder 26 can optionally be substantially 100percent paper-recyclable.

With reference to FIGS. 3 through 11, the mesh 12 can havemulti-directional flexibility, as well as improved resiliency relativeto prior art corrugate, in at least one of the longitudinal, lateral,and transverse directions X, Y, Z. In the illustrated embodiments, themesh 12 is flexible in each of the longitudinal, lateral, and transversedirections X, Y, Z. In the embodiment illustrated in FIG. 2, the mesh 12is formed in a single piece of corrugate 30. The legs 14 and nodes 16can be formed in the corrugate 30 mechanically, such as by a cuttingmachine. By way of non-limiting example, in such a cutting machine, thepiece of corrugate 30 can be inserted along the longitudinal direction Xinto an induction end of the machine and can be directed over a bladedroller (i.e., a cylinder with outwardly extending blades) or between apair of bladed rollers. The bladed roller(s) can carry blades orientedalong the longitudinal direction X, for example, and can cut a repeatingpattern of through-cuts in the corrugate 30 so as to transform thecorrugate 30 into the mesh 12. It is to be appreciated that theforegoing cutting machine represents merely one example of a mechanismfor forming the legs 14 and nodes 16 in the mesh 12, and othermechanisms are within the scope of the present disclosure.

Referring now to FIGS. 3 and 4, a portion of the mesh 12 of FIG. 2 isshown in an initial, unexpanded mesh configuration, such as when themesh 12 exits the cutting machine, for example. In FIG. 3, some of thenodes 16 are identified by dashed areas for visualization purposes. Thenodes 16 can include peripheral nodes 16 a located at the periphery 22of the mesh 12, as well as non-peripheral or internal nodes 16 b inwardof the periphery 22. The mesh 12 portion defines an area in thelongitudinal and lateral directions X, Y, which area is defined by afirst length L1 along the longitudinal direction X and a first width W1along the lateral direction Y.

Lateral edges of the legs 14 and nodes 16 of the mesh 12 can be definedby through-cuts 32 in the corrugate 30. The mesh pattern can beconfigured such that the nodes 16 are arranged in rows 34 of nodes 16and columns 36 of nodes 16. The nodes 16 of each row 34 can besubstantially aligned along a row axis 38 extending along the lateraldirection Y. Adjacent rows 34 can be spaced from each other along thelongitudinal direction X by a distance greater than zero. The nodes ofeach column 36 can be substantially aligned along a column axis 40extending along the longitudinal direction X. At least in the initialmesh configuration, the nodes 16 in adjacent node columns 36 can overlapeach other with respect to the lateral direction Y.

With reference to FIG. 3, one or more of the nodes 16 can define firstand second lateral edges 42, 44 spaced from each other along the lateraldirection Y, as well as first and second longitudinal ends 46, 48 spacedfrom each other along the longitudinal direction X. Each respective node16 can be connected to an adjacent node 16 by one or more legs 14. Inthe example embodiment illustrated in FIG. 3, each node 16 has eightlegs 14 extending therefrom, with two legs 14 connecting each node 16 toan adjacent node 16. It is to be appreciated that other leg 14/node 16quantities and/or geometries can be employed.

Each of the legs 14 can be elongated so as to define a longitudinal legaxis 50. In the illustrated embodiment, when the mesh 12 is in theinitial mesh configuration, the longitudinal leg axes 50 of each of thelegs 14 can be substantially parallel with one another. Additionally, inthe initial mesh configuration, the longitudinal leg axes 50 of each ofthe legs 14 can be oriented substantially along the longitudinaldirection X. As shown, in the initial mesh configuration, laterallyadjacent nodes 16 and laterally adjacent legs 14 can have minimal, ifany, gaps therebetween along the lateral direction Y.

Referring now to FIG. 4, the piece of corrugate 30, and thus the mesh 12also, defines a top mesh surface 52 and an opposed bottom mesh surface54 opposite each other substantially along the transverse direction Z.Fluting 56 is disposed between the top and bottom mesh surfaces 52, 54.Each of the nodes 16 can define a top node surface 58 that is defined bythe top mesh surface 52, as well as an opposed bottom node surface 60that is defined by the bottom mesh surface 54. Each node 16 also definesa transverse node axis 62 that is oriented substantially normal to thetop and bottom node surfaces 58, 60. As shown in FIG. 4, in the initialmesh configuration, the transverse node axes 62 extend generally nearalignment with the transverse direction Z. Additionally, each of thelegs 14 can define a top leg surface 64 that is defined by the top meshsurface 52, as well as an opposed bottom leg surface 66 that is definedby the bottom mesh surface 54. Each leg 14 also defines a transverse legaxis 68 that is oriented substantially normal to the top and bottom legsurfaces 64, 66. As shown in FIG. 4, in the initial mesh configuration,the transverse leg axes 68 extend generally near alignment with thetransverse direction Z.

Referring now to FIG. 5, the mesh 12 portion shown in FIG. 3 is nowshown in a first expanded configuration. In the first expandedconfiguration, the mesh portion 12 can define an area having a secondlength L2 along the longitudinal direction X and a second width W2 alongthe lateral direction Y. In the illustrated embodiments, the secondwidth W2 is greater than the first width W1, while the second length L2is slightly less than the first length L1. Thus, in the first expandedconfiguration, the mesh 12 portion is expanded or enlarged by stretchingalong the lateral direction Y and slightly contracted along thelongitudinal direction X as a result of the stretching. In theillustrated embodiments, the lateral expansion is greater than thelongitudinal contraction. In this manner, the area of the mesh 12portion increases from the initial configuration to the first expandedconfiguration.

As shown, in the first expanded configuration, the longitudinal leg axes50 can be offset from the longitudinal direction X. As the mesh 12expands laterally, the some of the through-cuts 32 expand into primarygaps 70 between the adjacent nodes 16 and/or legs 14. As the mesh 12 isexpands laterally, the primary gaps 70 increase in width along thelateral direction Y so as to define the boundaries of primary ones 18 aof the cells 18. In the illustrated embodiment, others of thethrough-cuts 32 expand into secondary gaps 72 that also increase inwidth between the pairs of legs 14 that interconnect each node 16 withan adjacent node 16. The secondary gaps 72 define secondary cells 18 bthat are narrower than the primary cells 18 a. As shown, the primarycells 18 a (which can constitute a majority of the cells 18) can eachhave a substantially hexagonal shape, providing the mesh 12 with asubstantially honeycomb pattern of primary cells 18 a. In particular,the six sides of a hexagon primary cell 18 a can be defined by (movingclockwise) a first leg 14 a extending from a first node 16 c, the firstlateral edge 42 of the first node 16 c, a second leg 14 b extending fromthe first node 16 c, a third leg 14 c extending from a second node 16 dthat is laterally spaced form the first node 16 c, the second lateraledge 44 of the second node 16 d, and a fourth leg 14 d extending fromthe second node 16 d. It is to be appreciated that patterns and othercell geometries are within the scope of the present disclosure.

Referring now to FIGS. 4 and 6, as the mesh 12 moves from the initialconfiguration to the first expanded configuration, the transverse nodeaxes 62 (that is, normal projections thereof in a plane extending alongthe lateral and transverse directions Y, Z) rotate away fromsubstantially near alignment with the transverse direction Z (FIG. 4) toa wider oblique angle α offset from the transverse direction Z (FIG. 6).Similarly, as the mesh 12 moves from the initial configuration to thefirst expanded configuration, the transverse leg axes 68 (or at leastprojections thereof in the lateral, transverse plane Y-Z) also rotateaway from substantially near alignment with the transverse direction Z(FIG. 4) to a wider oblique angle β offset from the transverse directionZ (FIG. 6). Preferably, oblique angles α and β are substantiallyequivalent.

Referring now to FIG. 7, the mesh 12 portion is now shown in a secondexpanded configuration, in which the lateral expansion is greater thanthat of the first expanded configuration. In the second expandedconfiguration, the area of the mesh portion 12 has a third width W2along the lateral direction Y that is greater than the second width W2,as well as third length L2 along the longitudinal direction X that isslightly less than the second length L2. Thus, in the second expandedconfiguration, the mesh 12 portion is expanded (by stretching) along thelateral direction Y and slightly contracted along the longitudinaldirection X relative to the first expanded configuration. As before, thelateral expansion is greater than the longitudinal contraction so thatthe area of the mesh 12 portion increases from the first to the secondexpanded configuration. Additionally, the primary and secondary gaps 70,72 in the mesh 12 are wider along the lateral direction Y in the secondexpanded configuration than in the first expanded configuration.

Referring now to FIGS. 6 and 8, as the mesh 12 moves from the first tothe second expanded configuration, the respective oblique angles α, β ofthe transverse node axes 62 and transverse leg axes 14 increase. In thismanner, as the mesh 12 is stretched laterally, the transverse axes 62,68 of the nodes 16 and legs 14 (or at least some, or preferably no lessthan a majority of the nodes and legs) are each reoriented. Accordingly,as the mesh 12 is laterally stretched, the legs 14 and nodes 16transition from a configuration in which the top and bottom nodesurfaces 58, 60 and the top and bottom leg surfaces 64, 66 become lessparallel with, and more perpendicular to, the outer layers 6, 8 of thepackaging cushion 2. As shown in FIGS. 6, and 8, in the first and secondexpanded configurations, the points of contact between the mesh 12 andthe outer layers 6, 8 occur at least primarily at the first and secondlateral edges 42, 44 of the nodes 16, increasing the compressivestrength of the mesh 12 at each node 16. The compressive strength of themesh 12 at each node 16 increases with the increased perpendicularitybetween the top and bottom node surfaces 58, 60 and the outer layers 6,8. Additionally, it has been observed that the average compressivestrength of the mesh 12 increases with increasing lateral expansion ofthe mesh 12. It has also been observed that the multi-directionalflexibility of the mesh 12 responsive to compressive forces along thetransverse direction Z increases with increased lateral expansion of themesh 12. Prior art corrugate, at least in some configurations, may havesimilar compressive strength relative to the packaging cushions 2disclosed herein. However, when a fold or crease is formed in prior artcorrugate that, for example, extends transversely through the corrugatelayer, the corrugate exhibits localized weakness in the area of the foldor crease. Prior art corrugate also has preferred bending along theflutes, which has limitations in packaging that needs to be bent inmultiple directions. In contrast to prior art corrugate, the inventorshave observed that, in each of the embodiments disclosed herein, thepackaging cushion 2 exhibits multi-directional flexibility responsive toeach of transverse, lateral and longitudinal compressive forces, as wellas to torsional forces. This multi-directional flexibility enables theseembodiments to bend without significantly impairing the performance ofthe packaging cushion 2.

Referring now to FIGS. 9 and 10, an additional embodiment of the mesh12′ is shown. The mesh 12′ may comprise packaging paper, such as kraftpaper, for example. The mesh 12′ of the present embodiment can beconfigured generally similarly to the mesh 12 described above withreference to FIGS. 2 through 8. In particular, the mesh 12′ includes aplurality of legs 14′ extending between a plurality of nodes 16′ so asto define a plurality of voids/cells 18′ in the mesh 12′. Some of thenodes 16′ in FIG. 9 are indicated by dashed areas for visualizationpurposes. As above, one or more of the nodes 16′ can define first andsecond lateral edges 42′, 44′ spaced from each other along the lateraldirection Y, as well as first and second longitudinal ends 46′, 48′spaced from each other along the longitudinal direction X. In theillustrated embodiment, each respective node 16′ can be connected to anadjacent node 16′ by a single leg 14′, with each internal node 16 b′having four legs 14 extending therefrom.

The edges of the legs 14′ and nodes 16′ of the mesh 12′ can be definedby through-cuts 32′ formed therein by a cutting machine (for example, apaper-cutting machine). As above, the legs 14′ and nodes 16′ can bearranged such that, as the mesh 12′ is stretched laterally, thethrough-cuts 32′ expand into gaps 70′ so as to define the cells 18. Thecells 18′ can each be hexagonal so as to define a honeycomb pattern inthe mesh 12′, although other cell geometries and other patterns arewithin the scope of the present disclosure.

Each of the nodes 16′ can define a top node surface 52′ and a bottomnode surface 54′ that are respectively defined by top and bottomsurfaces 52′, 54′ of the packaging from which the mesh 12′ was formed.Each node 16′ also defines a transverse node axis 62′ that is orientedsubstantially normal to the top and bottom node surfaces 52′, 54′. Eachof the legs 14′ can define a top leg surface 64′ and a bottom legsurface 66′ that are respectively defined by top and bottom surfaces52′, 54′ of the packaging. Each leg 14′ also defines a transverse legaxis 68′ that is oriented substantially normal to the top and bottom legsurfaces 64′, 66′.

As above, the mesh 12′ can be expanded laterally, such as by stretching,so that an area of the mesh 12′ increases. As shown in FIG. 9, in aninitial mesh configuration, the mesh 12′ defines a first length L1′along the longitudinal direction X and a first width W1′ along thelateral direction Y. As shown in FIG. 10, the mesh 12′ can be expandedto an expanded mesh configuration, wherein the mesh 12′ defines a secondlength L2′ that is slightly less than the first length L1′ and a secondwidth W2′ that is greater than the first width W1′.

Referring now to FIG. 11, in a similar manner to that described abovewith reference to FIGS. 6 and 8, as the mesh 12′ is expanded laterally,respective oblique angles α′, β′ of the transverse node axes 62′ andtransverse leg axes 14′ increase. In this manner, the top and bottomnode surfaces 58′, 60′ and the top and bottom leg surfaces 64′, 66′ eachbecome less parallel with, and more perpendicular to, the outer layers6, 8 of the packaging cushion 2. Accordingly, the inventors haveobserved that a packaging cushion 2 employing the mesh 12′ of thepresent embodiment exhibits similar multi-directional flexibilitybenefits to those set forth above with reference to FIGS. 3 through 8.

It is to be appreciated that while the illustrated embodiments showmeshes 12, 12′ may be formed of corrugate and packaging paper (such askraft paper), a mesh can similarly be formed of other materials,including paperboard, other paper-based packaging materials, metal, andplastic, such as recyclable plastic.

Referring now to FIG. 12, a package, such as a padded envelope 100, canemploy one or more packaging cushions 2 that are configured as set forthabove. While a padded envelope 100 is described herein, it is to beappreciated that virtually any type of package can employ one or more ofthe packaging cushions 2. The padded envelope 100 can include a firstpanel 102 overlaying a second panel 104. Each panel 102, 104 can includea packaging cushion 2 having a cushion layer 4 disposed between a firstor outer liner 6 and a second or inner liner 8. The cushion layer 4 ofeach panel 102, 104 can include a mesh 12 coupled to the liners 6, 8with a binder 20. The mesh 12 and binder 20 can each be configuredaccording to any of the respective embodiments set forth above.

The outer liners 6 can each define an outer surface 106 of therespective panel 102, 104 and the inner liners 8 can each define aninner surface 108 of the respective panel 102, 104. Each panel 102, 104can define a transverse liner axis 110 that extends substantially normalto the respective outer and inner surfaces 106, 108 (in FIG. 12, thetransverse liner axes 110 of the first and second panels 102, 104 arecoextensive). The inner liners 8 of the panels 102, 104 can collectivelydefine an internal storage compartment 112 of the envelope 100. Theinner liners 8 can be attached together with a package bond 114, whichcan employ any of the types of binders 20, 26 set forth above. Each ofthe liners 6, 8, meshes 12, and binders 20 of the panels 102, 104 can beformed of one or more paper-based materials that are curbsiderecyclable. Additionally, any labels applied to the package, as well asthe adhesives used therewith, can also be curbside recyclable. In thismanner, the padded envelope 100 can be curbside recyclable.

Referring now to FIGS. 13 and 14, padded packages 120 according toadditional embodiments can include a single packaging cushion 122wrapped around an item 124 (FIG. 14). As above, the packaging cushion122 can include an outer liner 126, an inner liner 128, and a mesh 12disposed in between the liners 126, 128. In FIG. 13, one such paddedpackage 120 a having a kraft mesh 12′ is shown alongside another suchpadded package 120 b having a corrugate mesh 12. In FIG. 13, portions ofthe outer liners 126 are transparent so that the meshes 12, 12′ arevisible. As above, each of the padded packages can be curbsiderecyclable. It is to be appreciated that other packaging productsincorporating packaging cushions 2 are within the scope of the presentdisclosure.

Referring now to FIG. 15, an example system 200 for making a cushioninglayer 2 can include a first zone 202 in which a supply 204 ofpaper-based product is located, such as a z-fold stack of raw corrugate30, or example. A second zone 206 can include a cutting machine 208employing bladed rollers 210, for example, to form the mesh 12. A thirdzone 212 can include one or more stretching rollers 214 to expand themesh 12 into an expanded configuration. A fourth zone 216 can include aglue vat roller 218 for disposing glue on a bottom surface of the mesh12. A fifth zone 220 can include a supply of kraft paper 222 forlamination on the bottom surface of the mesh. A sixth zone 224 caninclude another glue vat roller 226 for disposing glue on the topsurface of the mesh 12. A seventh zone 228 can include another supply ofkraft paper 230 for lamination on the top surface of the mesh 12. Aneighth zone 232 can define a fully formed paper-based packaging cushion2. The foregoing example system 200 represents merely one example ofvarious system configurations for making a paper-based packaging cushion2.

It should be noted that the illustrations and descriptions of theembodiments shown in the figures are for exemplary purposes only, andshould not be construed limiting the disclosure. One skilled in the artwill appreciate that the present disclosure contemplates variousembodiments. Additionally, it should be understood that the conceptsdescribed above with the above-described embodiments may be employedalone or in combination with any of the other embodiments describedabove. It should further be appreciated that the various alternativeembodiments described above with respect to one illustrated embodimentcan apply to all embodiments as described herein, unless otherwiseindicated. Also, the present invention is not intended to be limited byany description of drawbacks or problems with any prior art device.

Unless explicitly stated otherwise, each numerical value and rangeshould be interpreted as being approximate as if the word “about” or“approximately” preceded the value or range.

It should be understood that the steps of exemplary methods set forthherein are not necessarily required to be performed in the orderdescribed, and the order of the steps of such methods should beunderstood to be merely exemplary. Likewise, additional steps may beincluded in such methods, and certain steps may be omitted or combined,in methods consistent with various embodiments.

Although the elements in the following method claims, if any, arerecited in a particular sequence with corresponding labeling, unless theclaim recitations otherwise imply a particular sequence for implementingsome or all of those elements, those elements are not necessarilyintended to be limited to being implemented in that particular sequence.

What is claimed is:
 1. An envelope, comprising: one or more panelsorganized so as to define an internal compartment, wherein each of theone or more panels includes: a first liner defining an outer surface ofthe respective panel, a second liner defining an inner surface of therespective panel, the inner surface defining at least a portion of theinternal compartment; a transverse liner axis extending substantiallynormal to the inner and outer surfaces; a mesh bonded to one or both ofthe first and second liners, the mesh having a top mesh surface and anopposed bottom mesh surface, the mesh defining: a plurality of nodeseach defining 1) a top node surface defined by the top mesh surface, 2)a bottom node surface defined by the bottom mesh surface, and 3) atransverse node axis extending substantially normal to the top andbottom node surfaces, wherein the transverse node axes of at least someof the plurality of nodes are each oriented at an oblique angle relativeto the transverse liner axis; and a plurality of legs interconnectingthe plurality of nodes, wherein the plurality of nodes and the pluralityof legs have multi-directional flexibility; and a binder that bonds themesh to the one or both of the first and second liners, wherein thebinder adheres at least a subset of the plurality of legs and at least asubset of the plurality of nodes together to one or both of the firstand second liners.
 2. The envelope of claim 1, wherein the one or morepanels comprises a single panel that is wrapped around itself so that 1)the inner surface of the second liner defines the internal compartment,and 2) the outer surface of the first liner defines an exterior of theenvelope.
 3. The envelope of claim 1, wherein the one or more panelscomprises a pair of panels each defining a periphery, wherein the pairof panels are bonded together at a portion of the respective peripheriesso as to define the internal compartment between the pair of panels. 4.The envelope of claim 1, wherein each of the first and second linerscomprises kraft paper, and the mesh comprises one of kraft paper,paperboard, and corrugate.
 5. The envelope of claim 1, wherein thebinder is a substantially entirely paper-recyclable binder.
 6. Theenvelope of claim 1, wherein each of the first and second linerscomprises kraft paper, and the mesh comprises kraft paper.
 7. Anenvelope, comprising: a panel folded over itself so as to define aninternal compartment, wherein the panel includes: a first liner definingan outer surface of the panel, a second liner defining an inner surfaceof the panel, the inner surface defining at least a portion of theinternal compartment; a transverse liner axis extending substantiallynormal to the inner and outer surfaces; a mesh disposed between thefirst and second liners, the mesh having a top mesh surface and anopposed bottom mesh surface, the mesh defining: a plurality of nodeseach defining 1) a top node surface defined by the top mesh surface, 2)a bottom node surface defined by the bottom mesh surface, and 3) atransverse node axis extending substantially normal to the top andbottom node surfaces, wherein the transverse node axes of at least someof the plurality of nodes are each oriented at an oblique angle relativeto the transverse liner axis; and a plurality of legs interconnectingthe plurality of nodes, wherein the plurality of nodes and the pluralityof legs have multi-directional flexibility; and a binder that bonds themesh to at least one of the first and second liners, wherein the binderadheres at least a subset of the plurality of legs and at least a subsetof the plurality of nodes to the at least one of the first and secondliners.
 8. The envelope of claim 7, wherein the binder adheres at leasta majority of the plurality of nodes to the at least one of the firstand second liners.
 9. The envelope of claim 7, wherein the binder isapplied as an even coating of adhesive to the at least one of the firstand second liners.
 10. The envelope of claim 7, wherein the innersurface of the second liner defines the internal compartment, and theouter surface of the first liner defines an exterior of the envelope.11. The envelope of claim 7, wherein each of the first and second linerscomprises kraft paper, and the mesh comprises kraft paper.
 12. Theenvelope of claim 11, wherein the binder is a substantially entirelypaper-recyclable binder.
 13. The envelope of claim 7, wherein the panelhas a first portion and a second portion folded over each other, thefirst and second portions each define a periphery, and the first andsecond portions are bonded together along a portion of the respectiveperipheries so as to define the internal compartment.
 14. The envelopeof claim 13, further comprising a second binder that binds the first andsecond portions of the panel together.
 15. The envelope of claim 14,wherein the binder and the second binder are each a substantiallyentirely paper-recyclable binder.
 16. An envelope, comprising: a panelfolded over itself so as to define an internal compartment, wherein thepanel includes: a liner having an inner surface and an outer surface,wherein the outer surface defines an outer surface of the panel, and theinner surface is adjacent an internal compartment of the folded panel; atransverse liner axis extending substantially normal to the inner andouter surfaces; a mesh attached to the liner, the mesh having a top meshsurface and an opposed bottom mesh surface, the mesh defining: aplurality of nodes each defining 1) a top node surface defined by thetop mesh surface, 2) a bottom node surface defined by the bottom meshsurface, and 3) a transverse node axis extending substantially normal tothe top and bottom node surfaces, wherein the transverse node axes of atleast some of the plurality of nodes are each oriented at an obliqueangle relative to the transverse liner axis; and a plurality of legsinterconnecting the plurality of nodes, wherein the plurality of nodesand the plurality of legs have multi-directional flexibility; and abinder that bonds the mesh to the inner surface of the liner, whereinthe binder adheres at least a subset of the plurality of legs and atleast a subset of the plurality of nodes to the inner surface.
 17. Theenvelope of claim 16, wherein each of the first and second linerscomprises kraft paper, and the mesh comprises kraft paper.
 18. Theenvelope of claim 17, wherein the binder is a substantially entirelypaper-recyclable binder.
 19. The envelope of claim 16, wherein the panelhas a first portion and a second portion folded over each other, thefirst and second portions each define a periphery, and the first andsecond portions are bonded together along a portion of the respectiveperipheries so as to define the internal compartment.
 20. The envelopeof claim 19, further comprising a second binder that binds the first andsecond portions of the panel together.